Custom Coke Vibration Screen Factory
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Is Your Coke Screening Costing You $50,000 Par heure en temps d'arrêt?
Every plant manager in the metallurgical coke industry knows the math: a 30minute screen deck change on a standard unit costs roughly $25,000 en production perdue. Add in the hidden costs—premature blinding from inconsistent particle sizes, structural fatigue from improper vibration angles, and the constant battle against abrasive coke dust wearing down standard steel decks.
Your current screening setup likely faces three critical failures:
1. Blinding and pegging dans le 2580 fraction en mm, requiring manual cleaning every 46 heures.
2. Structural cracking at weld points due to highG force resonance not matched to your specific material density.
3. Inconsistent cut accuracy leading to downstream crusher overload or customer rejection of oversize product.
The question is not si you need a better screen—it is comment to get a machine engineered for your specific coke blend, throughput tonnage, and existing plant footprint.
Présentation du produit: The Custom Coke Vibration Screen
This is a heavyduty, linearmotion or circularmotion vibrating screen, purposebuilt for classifying metallurgical coke, coke de fonderie, et coke de pétrole. Contrairement aux unités disponibles dans le commerce, this equipment is designed from your material sample and site survey.
Flux de travail opérationnel:
1. Distribution d'aliments: Material enters via a flared feed box, designed to minimize impact velocity and prevent deck damage.
2. Stratification: A customtuned vibration frequency (typiquement 7501000 RPM) separates fines (<10mm) from the main product stream.
3. Classification: Multideck configurations (24 ponts) separate into commercial fractions: 1025mm, 2550mm, 5080mm, and +80mm.
4. Décharge surdimensionnée: Oversize material is directed to a crusher recirculation loop or direct loadout chute.
5. Suppression des amendes: Undersize material exits through a dedicated discharge spout, minimizing dust recirculation.
Champ d'application:
- Convient pour: Green coke, calcined coke, coke de haut fourneau, et coke de fonderie.
- Limites: Not designed for wet screening (humidité >8%) without specialized polyurethane decks. Not recommended for materials with high clay content (>5%) sans présélection.
- Standard Custom Build (2pont, 200 TPH): $85,000 $120,000
- MidRange Custom Build (3pont, 400 TPH, ceramiclined): $145,000 $195,000
- HighCapacity Custom Build (4pont, 600+ TPH, VFD, dust system): $220,000 $310,000
- Vibration monitoring system with remote alerts: +$8,500
- Hydraulic angle adjustment: +$12,000
- Stainless steel contact surfaces: +$18,000
- Spare deck kit (one full set): +$22,000
- Garantie standard: 36 months on structural frame, 12 months on vibrating components
- Contrat de service étendu: Includes biannual inspection, remplacement des roulements à 20,000 heures, and priority onsite support: $4,500/année
- Garantie de performance: We guarantee 94% screening efficiency on your specified cut size or we adjust the machine at no cost.
- Filet 30 conditions pour les acheteurs qualifiés
- 12month leasetoown option (monthly payments from $7,500)
- 5year equipment loan at 6.9% APR through partner lenders
Fonctionnalités principales
Custom Deck Material Selection | Base technique: Abrasion Resistance Engineering | Avantage opérationnel: 3x longer service life vs. standard AR400 steel | Impact sur le retour sur investissement: Reduces annual deck replacement costs by 4060%
Your coke has a specific abrasion index. We match deck material—either 500 Brinell Hardox, ceramiclined panels, or modular polyurethane—to your specific coke hardness. Field data from a 500 TPH plant in West Virginia showed a 2.8x increase in deck life after switching from standard steel to customhardened panels.
Tuned Vibration Frequency & Amplitude | Base technique: Resonance Avoidance & Material Stratification Physics | Avantage opérationnel: Eliminates structural cracking at weld joints | Impact sur le retour sur investissement: Reduces unscheduled maintenance downtime by 70%
Standard screens run at fixed RPM. Our custom units are tuned to your material’s bulk density (typiquement 0.81.2 t/m³ pour le coke) et forme des particules. This prevents the "harmonic bounce" that causes frame fatigue. One Midwest foundry reported zero structural cracks over 18 months after installation.
QuickChange Deck System | Base technique: Modular Tensioning Mechanism | Avantage opérationnel: Deck change in under 20 minutes vs. 2 heures | Impact sur le retour sur investissement: Récupère 1.5 hours of production per changeout
Bolted and pinned deck frames allow singleperson replacement without welding or cutting. This is critical for plants running 24/7 operations where every minute of downtime is lost revenue.
Confinement de la poussière intégré | Base technique: Negative Pressure Sealing | Avantage opérationnel: Meets OSHA PEL for respirable coke dust (<0.15 mg/m³) | Impact sur le retour sur investissement: Évite les amendes potentielles de $13,000+ par infraction
Fulllength rubber skirts, sealed inspection doors, and a dedicated dust collection port (612 inch diameter) connect to your existing baghouse. No aftermarket retrofitting required.
Variable Angle Adjustment (025°) | Base technique: Material Flow Control | Avantage opérationnel: Optimizes retention time for different coke grades | Impact sur le retour sur investissement: Améliore l’efficacité du dépistage en 58% across product changes
Hydraulic or manual adjustment allows your operators to change the deck angle without stopping the machine. This is essential when switching between blast furnace coke (requires longer retention) and nut coke (requires faster throughput).
Ensemble d'arbre excentrique robuste | Base technique: Tapered Roller Bearings & Forged Shaft | Avantage opérationnel: 50,000hour bearing life under full load | Impact sur le retour sur investissement: Eliminates one major rebuild cycle over 5 années
Standard screens use spherical roller bearings that fail at 15,00020,000 hours under coke’s abrasive load. Our assembly uses oversized, sealed tapered roller bearings with a dedicated oil lubrication system.
Avantages compétitifs
| Mesure de performances | Norme de l'industrie (Hors de l'étagère) | Écran vibrant de coke personnalisé | Avantage (% Amélioration) |
| : | : | : | : |
| Efficacité du dépistage (25mm de coupe) | 8588% | 9497% | +910% |
| Deck Service Life (heures) | 2,500 3,500 | 8,000 12,000 | +220240% |
| ChangeOut Time (par pont) | 90120 minutes | 1520 minutes | 83% |
| Structural Warranty Period | 12 mois | 36 mois | +200% |
| Consommation d'énergie (per ton) | 0.45 kWh/t | 0.32 kWh/t | 29% |
| Niveau de bruit (à 1 mètre) | 92 dB(UN) | 82 dB(UN) | 11% (meets OSHA limits) |
Spécifications techniques (Customizable per Application)
| Paramètre | Gamme Standard | Custom Option |
| : | : | : |
| Capacité nominale | 100 600 TPH | Jusqu'à 1,000 TPH (dualdrive) |
| Configuration du pont | 2 ou 3 ponts | 1 à 4 ponts |
| Zone d'écran | 16 40 sq. pi. par pont | Jusqu'à 60 sq. pi. par pont |
| Puissance du moteur | 15 40 HP (1130 kW) | Jusqu'à 75 HP (56 kW) |
| Fréquence des vibrations | 750 1,000 RPM | 600 1,200 RPM (VFDprêt) |
| Amplitude (Accident vasculaire cérébral) | 8 12 mm | 6 16 mm |
| Deck Material | Acier AR400 (400 BHN) | Hardox 500, Ceramic Tile, Polyuréthane (4060 Rive D) |
| Matériau du cadre | Acier au carbone (A36) | Acier résistant à l'abrasion (AR500) or Stainless Steel (304/316) |
| Température de fonctionnement | 20°C to 80°C | 40°C to 120°C (with hightemp seals) |
| Dust Port Size | 6inch diameter | 8, 10, or 12inch diameter |
| Poids (env.) | 8,000 18,000 livres | Custom per design |
Scénarios d'application
Blast Furnace Coke Producer (600 Usine TPH)
Défi: The plant was experiencing 12% fines carryover into the blast furnace feed, causing increased slag volume and higher coke consumption. Standard screens could not achieve the required 95% efficiency on the 25mm cut.
Solution: Installation of a custom 3deck, 40 sq. pi. screen with tuned frequency for 0.9 t/m³ bulk density and ceramiclined decks.
Résultats: Efficacité du dépistage améliorée à 96.5%. Report d’amendes réduit à 3.5%. Annual coke savings of $1.2 million due to reduced blast furnace consumption.
Foundry Coke Processor (150 Usine TPH)
Défi: Frequent deck blinding on the 50mm cut due to irregular particle shapes. Manual cleaning required every 4 heures, coût 30 minutes of production per shift.
Solution: Custom screen with variable angle adjustment (set to 18°) and polyurethane modular decks with selfcleaning pin holes.
Résultats: Blinding eliminated. Deck cleaning interval extended to 72 heures. Temps de disponibilité de la production augmenté de 12%, ajout 1,800 tons per year.
Petroleum Coke Calcining Facility (400 TPH)
Défi: High wear rates on standard steel decks—replacement every 3 mois. Dust emissions exceeded local air quality permits.
Solution: Custom screen with Hardox 500 decks and integrated negativepressure dust containment system.
Résultats: Deck life extended to 14 mois. Dust emissions reduced to 0.08 mg/m³, well below permit limits. Annual maintenance cost reduced by $180,000.
Considérations commerciales
Niveaux de tarification des équipements (Estimated FOB Factory):
Fonctionnalités facultatives:
Forfaits de services:
Options de financement:
FAQ
1. Can this custom screen handle both green coke and calcined coke without modification?
Oui, but a deck change may be required. Green coke (higher moisture, lower abrasion) performs best with polyurethane decks. Calcined coke (higher abrasion, lower moisture) requires Hardox or ceramiclined decks. The frame and drive system are identical for both.
2. What is the lead time for a custombuilt unit?
Standard custom builds require 812 weeks from order approval. This includes material sampling, engineering review, fabrication, and factory testing. Commandes urgentes (68 semaines) are available at a 15% prime.
3. How does your efficiency guarantee work?
We provide a written guarantee that your custom screen will achieve 94% screening efficiency on the specified cut size (±2mm) at your rated capacity. If it does not, we will modify the vibration settings or deck configuration at our expense until the guarantee is met.
4. Quelle formation en maintenance proposez-vous aux opérateurs d'usine?
We include a 2day onsite training program covering daily inspection procedures, bearing lubrication schedules, deck tensioning techniques, and troubleshooting common issues like material carryover or uneven distribution.
5. Can this screen be retrofitted into an existing plant footprint?
Oui. Our engineering team conducts a site survey to measure existing support structures, chute locations, et branchements électriques. We design the screen to match your existing bolt pattern and discharge elevations, minimizing installation costs.
6. What is the expected lifespan of the vibrating mechanism?
The eccentric shaft assembly is rated for 50,000 hours of continuous operation under full load. With proper lubrication (oil changes every 2,000 heures), the bearings typically last 25,00030,000 hours before requiring replacement.
7. Do you offer a tradein program for old screens?
Oui. We offer a tradein credit of $5,000 $15,000 depending on the age, condition, and size of your existing equipment. This credit is applied directly to your custom screen purchase.